Vented insulation for nail based applications

ABSTRACT

A vented insulator for use in nail based construction. A sheet insulator includes a base having integrally formed thereon a plurality of upwardly extending nodes of uniform size. The nodes are uniformly distributed across the length and width of the base forming a plurality of air ventilation channels. The insulation is attached to and positioned between an internally located structural deck, such as a ceiling, and an outwardly located construction, such as a roof.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of the filing date of U.S. Provisional Application No. 60/653,612, filed on Feb. 16, 2005, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates generally to the field of building construction and more specifically, construction utilizing insulation.

DESCRIPTION OF THE PRIOR ART

It is the practice to install blown and/or sheet insulation within an attic of a building to limit heat flow through the ceiling. Typically, the insulation is positioned immediately atop the ceiling between rafters. In certain cases, attic space either does not exist or is insufficient in size to allow for insertion of the insulation. For example, in cathedral ceilings, the ceiling extends upwardly adjacent the roof and thus, the insulation must be positioned between the ceiling and roof. In the event spacing is not provided immediately beneath the roof for air ventilation, the shingles may rapidly deteriorate. Shingle manufactures therefore may not extend their warranty in such construction. In addition, certain building codes require a minimum air ventilation depth beneath the roof of at least one inch.

In order to solve the aforementioned problem, it has been the practice to insert an assembly composed of a flat rigid sheet of insulation atop of which are mounted a plurality of spacers secured to the sheet by adhesive. The spacers are configured as rails which extend to a substantial portion of the length of the rigid sheet. A layer of plywood or plastic panel rests atop the rails and the roof rests atop the plywood or panel thereby providing channels between the sheet and the roof for air to flow therethrough providing ventilation.

Typically, fasteners, including nails or screws are extended through the roof, and cover board passing through the rails and sheet into wood panels or structure located beneath the insulation board securing the combination together. Since the rails are spaced apart both lengthwise and widthwise across the sheet, it is difficult to align the fasteners from the roof to pass through the ridges. Further, the ridges are spaced sufficiently apart allowing the roof to bow between ridges if excessive or inconsistent downward pressure is applied to the roof. The bowing is known in the industry as denting. Thus, not only is a non-attractive external appearance provided but also the construction is not structural.

The assembly of the rails to the sheet provides a significant disadvantage in that effort must be expended constructing the base sheet and rail assembly adding to the overall cost of the construction.

Disclosed herein is a one piece or integral insulator having a plurality of spacers formed atop the insulating sheet with the spacers provided in a uniform pattern allowing for cross air ventilation through the length and width of the construction. The uniform pattern of spacer location along with the spacer size allows fasteners to be extended therethrough while eliminating the bowing or denting problem previously discussed. Further, the technique of construction allows for the insulation to be produced from extruded polystyrene, expanded polystyrene, or polyisocyanurate.

SUMMARY OF THE INVENTION

The preferred embodiment of the present invention includes a one piece integral insulator including a flat sheet with a plurality of insulating spacers formed there atop. The spacers or nodes are uniformly fabricated across the length and width of the sheet and are sized to provide suitable air ventilation channels.

The insulation may be positioned between a roof and cathedral ceiling creating cross air ventilation channels while eliminating bowing or denting of the roof.

It is an object of the present invention to provide a new and improved vented insulation positionable between a ceiling roof.

A further object of the present invention is to provide a one piece integral insulation including a flat sheet with a plurality of insulating nodes formed thereatop in a uniform pattern.

Yet another object of the present invention is to provide a new and improved method of producing insulation for use between a ceiling and roof.

An additional object of the present invention is to provide the aforementioned insulation from rigid extruded polystyrene, expanded polystyrene, or polyisocyanurate insulation materials.

Related objects and advantages of the present invention will be apparent from the following description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary cross-sectional view of a cathedral ceiling within a building having the insulation incorporating the present invention.

FIG. 2 is an enlarged perspective view of the insulation utilized in the construction of the FIG. 1.

FIG. 3 is an enlarged cross-sectional view taken along the line 3-3 and viewed in the direction of the arrows.

FIG. 4 is a diagram of a block of insulating material positioned atop a conveyor with the block movable toward a hot wire severing device for producing the nodes of the insulating sheet of FIG. 2.

FIG. 5 is a perspective view of block 60 of FIG. 4 after the block has passed one time through the severing device shown in FIG. 4.

FIG. 6 is the same view as FIG. 5 only with the block rotated 90 degrees and after the block as passed through the severing device for a second time.

DESCRIPTION OF THE PREFERRED EMBODIMENT

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated device, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

Referring now more particularly to FIG. 1, there is shown a fragmentary cross-sectional view of a cathedral ceiling 20. The ceiling includes a plurality of wood planks interlocked together by conventional tongue and groove construction. For example, planks 27 and 28 are secured together by a tongue and groove combination 29. The planks may be produced from wood or other suitable materials. The planks extend upwardly at an acute angle relative to the horizontal forming the traditional cathedral ceiling appearance.

Immediately atop planks 21 are mounted a plurality of insulation boards 22. Boards 22 are of conventional construction and may be produced from a variety of insulating materials. Importantly, the adjacent seams or edges of each board 22 are offset relative to the intersection of adjacent wood planks 21. For example, the insulating seam between insulating boards 30 and 31 is located between the opposite ends or edges of wood plank 27 minimizing air flow through the seams of the insulating boards and wood planks.

Immediately atop insulating boards 22 are located the insulating sheets 23 incorporating the present invention. Sheets 23 have a plurality of upwardly turned nodes forming channels between the nodes. A conventional board 24, typically produced of plywood rests atop the nodes of insulating sheets 23 with roofing paper 25 then being positioned atop panels 24. Shingles 26 are being fastened in the conventional manner being located outwardly of roofing paper 25.

The preferred embodiment of insulator 23 includes a flat sheet 40 (FIG. 2) with a plurality of spacers or nodes 41 positioned in a uniform pattern across the length and width of sheet 40. For example, nodes 41 are aligned in a plurality of rows extending the length of the sheet with one row shown by arrow 42. Likewise, nodes 41 are positioned across the width of the sheet in a uniform pattern forming, for example row 43. The nodes in each lengthwise extending row, such as row 42 are spaced equally apart. Likewise, the nodes in the widthwise extending rows, such as row 43, are spaced equally apart. Thus, the channel or spacing 44 is equal between each node 41 provided in row 42. Likewise, the channel or spacing 45 is equal between each node 41 provided in row 43. As a result, maximum air ventilation is achieved across the length and width of the insulator.

Each node forms an approximate one-inch cube. In other words, the length, width and height of each node is approximately one inch. Further, the spacing 44 between each node is approximately one inch as is the spacing 45 between each node. A uniform pattern is therefore achieved. The nodes are positioned sufficiently close to each other to prevent bowing or denting of the roof as downward pressure is applied to the roof such as, for example, by fasteners extending through the roof and insulator that may or may not be aligned with nodes 41.

The nodes extend perpendicularly upward or outward from sheet 40 forming a right angle α (FIG. 3) between the four outwardly extending sides of each node and the outwardly facing surface of sheet 40.

In order to form the nodes 41 integrally atop sheet 40 providing for a one piece construction, a block of insulating material is passed through a wire severing device, rotated 90 degrees and then passed through the wire severing device a second time.

Block 60 (FIG. 4) is shown resting atop a conventional conveyor belt and movable in the direction of arrow 68 towards a conventional wire severing device 61. Device 61 includes a plurality of hot wires or vibrating wires 62 spaced apart and extending across the width or the conveyer to contact the block 60 and sever the block into a plurality of insulating panels 70-74. Alternatively, block 60 may initially be composed of the separate panels 70-74. Such a wire severing device 61 is available from Gateway Precision Technologies, 12727 Riley Street, Holland, Mich. 49424 under model number R3700A.

Once block 60 is composed of a plurality of separate panels, such as panels 70-74, then the stack of panels is moved in the direction of arrow 68 through severing device 61 to form a plurality of ridges for each separate panel such as depicted in FIG. 5. Thus, each panel 70-74 is severed into two separate pieces forming respectively assemblies 63-67 each having a top half and a bottom half.

Assembly 63 will now be described it being understood an identical description applies to assemblies 64-67. Assembly 63 consists of a bottom half portion 63 a and a top half portion 63 b with the bottom half portion having a plurality of male portions or ridges extending upwardly into complementary sized and downwardly facing channels formed in top half portion 63 b. The ridges and channels in assembly 63 are formed by moving assembly 63 in the direction of arrow 68 through device 61 so that wire 62 a severs assembly 63 into a bottom half portion 63 a and top half portion 63 b. By moving wire 62 a vertically in the direction of arrow 69, the ridges and channels are formed in assembly 63. For example, with block 60 moving in the direction of arrow 68, wire 62 a contacts block 60. With wire 62 a then moving upwardly, side surface 63 c of the first ridge is formed. With wire 62 a held stationary, and block 60 continuing in the direction of arrow 68, top horizontal ridge surface 63 d is formed. Continued movement of block 60 in the direction of arrow 68 with wire 62 a then moving downwardly forms the opposite ridge side 63 e. In a similar fashions the remaining ridges and channels of assembly 63 are formed. Likewise, the ridges and channels of the remaining assemblies 64-67 are formed by moving the remaining wires in device 61 in a manner identical to the movement of wire 62 a Thus, upon completion of block 60 moving through device 61, block 60 is formed as depicted in FIG. 5 by five separate assemblies with each assembly having a top and bottom half potion mated together by a plurality of ridges and complementary receiving channels.

Block 60 is then rotated 90 degrees and passed again through device 61 in the direction of arrow 68. Alternatively, a second severing device 61 may be located downstream of device 61 with a suitable turntable provided for the rotation of block 60.

Once block 60 has been rotated 90 degrees, the end of the ridges or side 70 of block 60 will be facing severing device 61 with the individual wire 62 then contacting side 70 as the block moves in the direction of arrow 68. Repeated upward and downward movement of wire 62 will then cut each ridge into a plurality of nodes. Thus, the top half portion of each assembly will form a plurality of nodes extending across the length and width of the downwardly facing surface of the top half portion in a uniform pattern as previously described for sheet 40 and node 41. Simultaneously, a plurality of spaced apart nodes will be formed in the bottom half portion of each panel that extend in uniform pattern across the length and width of the upwardly facing surface of the bottom half portion.

The insulator disclosed herein provides a vented insulation for a nail or screw based application such as shown for the cathedral ceiling of FIG. 1. The device can equally be utilized in the same fashion over a metal deck underlay and thus is particularly suitable for any type of structural deck. In the event the construction is to utilize a metal structural deck in lieu of a wooden structural deck, then the shingles are replaced with a conventional seam metal outer layer.

The severing device 61 is commercially available and may take the form of either a plurality of parallel hot wires that cut through the insulation by direct heat or may take the form of a plurality of parallel vibrating wires that vibrate at a sufficient frequency to likewise cut the insulation by heat. Typically, such wires operate at a temperature of approximately 170 degrees Fahrenheit.

The construction and method of construction disclosed herein is particularly unique in that different insulating materials may be utilized including extruded and expanded polystyrene as well as polyisocyanurate. In the case of polyisocyanurate insulating blocks, the vibrating wire technique provides superior results as compared to a hot wire technique.

Many variations are contemplated and included in the present invention. For example, the length, width and height of the nodes may be of selected sizes; however, the nodes must be at least one inch high by one inch in width and length in order to achieve the one inch channel; however, each node must have a minimum one inch wide, one inch length, and one inch height to comply with the code requirements on one inch air ventilation channels.

In the embodiment shown in FIG. 1, the wooden planks 21 are two inches by six inches whereas the insulation boards 22 are produced by Styrofoam. Further, wood panel 24 has a 7/16 thickness and roofing paper 25 is commercially available 15 pound felt paper. Insulator 23 has many advantages as compared to the prior construction. For example, the insulation is lightweight and easy to handle and is especially useful in cathedral ceilings, commercial and institutional buildings, and log homes where attic space does not allow for conventional insulation. Insulation 23 may be produced from a thermally efficient extruded and expanded polystyrene insulation and consists of closed cells. The insulation may also be produced from polyisocyanurate material. In the preferred embodiment, the insulation is two inches thick and is produced in sheets 48 inches wide by 48 inches in length. The uniform pattern of the nodes allows for automatic cross ventilation. The physical properties of insulation 23 depending upon whether the insulation is produced from extruded polystyrene, expanded polystyrene, or polyisocyanurate and is as follows: ASTM Extruded Expanded Poly- Properties Method Polystyrene Polystyrene isocyanurate Compressive D1621 25 Typical 15 16 Strength Flexural C203 50 25 40 Strength Water C272 .03 4.0 5.0 Absorption Water Vapor E96 Less than 1 5.0 5.0 Permeance Dimensional D2126 2.0 Percent 2.0 percent 4.0 Stability Federal C578-04 or Type IV for Type 1 for Type II Specification C1289 C578-04 C578-04 Class 1 for C1289 Max use Temp. N/A 165 degrees 165 degrees N/A Flame Spread E84 5 5 25 Smoke E84 165 165 Development

While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected. 

1. A vented insulation system for nail based roofs comprising: a support with an upwardly facing supporting surface; a first sheet of insulation material mounted atop said support and including a bottom surface positioned atop said support and further including an upwardly facing first surface with said first surface extending in a widthwise direction and a lengthwise direction, said sheet has a plurality of first nodes extending upwardly from said first surface and being distributed across said widthwise direction and said lengthwise direction and defining a plurality of first ventilation channels and a plurality of second ventilation channels extending respectively in said widthwise direction and said lengthwise direction; a weather resistant outer covering positioned atop said nodes with said first ventilation channels and said second ventilation channels allowing air to circulate beneath said outer covering; and, a plurality of fasteners extending through said outer covering into said nodes fixedly securing said outer covering to said sheet.
 2. The vented insulation system of claim 1 wherein: said nodes are integrally formed on said first sheet.
 3. The vented insulation system of claim 2 wherein: said first sheet is produced from a group including rigid extruded polystyrene, expanded polystyrene, or polyisocyanurate material.
 4. The vented insulation system of claim 1 wherein: said nodes are arranged in first parallel rows extending in said widthwise direction and in a plurality of second rows extending in said lengthwise direction positioning said first ventilation channels perpendicularly to said second ventilation channels.
 5. The vented insulation system of claim 4 wherein: said nodes in each of said first parallel rows are spaced evenly apart and in each of said second parallel rows are spaced evenly apart providing a uniform pattern of nodes positioned across said sheet.
 6. The vented insulation system of claim 5 wherein: said nodes each have an approximate one inch width, an approximate one inch length, and an approximate one inch height.
 7. The vented insulation of system of claim 1 and further comprising: a second sheet of insulation material mounted atop said support in side by side fashion with respect to said first sheet, said second sheet including a bottom surface positioned atop said support and further including an upwardly facing second surface with said second surface extending in a second widthwise direction and a second lengthwise direction, said second sheet has a plurality of second nodes extending upwardly from said second surface and being distributed across said second widthwise direction and said second lengthwise direction and defining a plurality of third ventilation channels and a plurality of fourth ventilation channels extending respectively in said widthwise direction and said lengthwise direction, said first sheet and said second sheet formed together with said first nodes mating with said second nodes with said first sheet being separated from said second sheet so said second sheet may positioned atop said support with said first sheet in side by side fashion.
 8. A roof for a building comprising: a plurality of wooden base planks secured together; a plurality of insulation layers positioned atop said base planks; a plurality of sheets of insulation material positioned in side by side fashion and mounted atop said planks and insulation layers and each including a bottom surface positioned atop said insulation layers and further including an inwardly facing first surface with said first surface extending in a widthwise direction and a lengthwise direction, each sheet has a plurality of first nodes extending upwardly from said first surface and being distributed across said widthwise direction and said lengthwise direction and defining a plurality of first ventilation channels and a plurality of second ventilation channels extending respectively in said widthwise direction and said lengthwise direction; a weather resistant outer covering positioned atop said nodes with said first ventilation channels and said second ventilation channels allowing air to circulate between said sheets of insulation material and said outer covering; and, a plurality of fasteners extending through said outer covering into said nodes fixedly securing said outer covering to said sheet.
 9. The roof of claim 8 wherein: said nodes are integrally formed on said sheets.
 10. The vented insulation system of claim 9 wherein: said nodes are arranged in first parallel rows extending in said widthwise direction and in a plurality of second rows extending in said lengthwise direction positioning said first ventilation channels perpendicularly to said second ventilation channels.
 11. The vented insulation system of claim 10 wherein: said nodes in each of said first parallel rows are spaced evenly apart and in each of said second parallel rows are spaced evenly apart providing a uniform pattern of nodes positioned across said sheet.
 12. A vented insulation sheet for nail based applications comprising: a first sheet of insulation material including a bottom surface and an upwardly facing surface with said upwardly facing surface extending in a widthwise direction and a lengthwise direction, said sheet having a plurality of first nodes extending upwardly from said upwardly facing surface and being distributed across said widthwise direction and said lengthwise direction and defining a plurality of first ventilation channels and a plurality of second ventilation channels extending respectively in said widthwise direction and said lengthwise direction.
 13. The vented insulation sheet of claim 12 wherein: said nodes are integrally formed on said sheet.
 14. The vented insulation sheet of claim 13 wherein: said sheet is produced from a group including rigid extruded polystyrene, expanded polystyrene, or polyisocyanurate material.
 15. The vented insulation sheet of claim 14 wherein: said nodes are arranged in first parallel rows extending in said widthwise direction and in a plurality of second rows extending in said lengthwise direction positioning said first ventilation channels perpendicularly to said second ventilation channels.
 16. The vented insulation sheet of claim 15 wherein: said nodes in each of said first parallel rows are spaced evenly apart and in each of said second parallel rows are spaced evenly apart providing a uniform pattern of nodes positioned across said sheet.
 17. The vented insulation sheet of claim 16 wherein: said nodes each have an approximate one inch width, an approximate one inch length, and an approximate one inch height.
 18. The vented insulation sheet of claim 17 wherein: said sheet constructed to include a top half portion and a bottom half portion that are separable, said bottom half portion has an upwardly facing bottom half surface and said top half portion has a downwardly facing top half surface that mates with said upwardly facing bottom half surface until separated and repositioned in said side by side fashion with said downwardly facing surface then facing upwardly, said bottom half surface and said top half surface extending in a widthwise direction and a lengthwise direction, said top half portion and said bottom half portion have a plurality of nodes extending outwardly respectively from said top half surface and said bottom half surface and being distributed across said widthwise direction and said lengthwise direction defining a plurality of first ventilation channels and a plurality of second ventilation channels extending respectively in said widthwise direction and said lengthwise direction.
 19. The vented insulation sheet of claim 18 wherein: said nodes of said top half portion and of said bottom half portion are offset from each other when said top half portion is mated atop and to said bottom half portion. 